PCB Electrical Connector Structure for Simpler Sealed Assembly
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Solution Overview
Problem
Conventional electrical connectors with insulated rubber cores and metal terminals require expensive and complex manufacturing processes, including metal stamping and injection molding, leading to high costs and complexity.
Innovation Solution
The use of a circuit board with electrical conductors and soldering pads instead of traditional rubber cores and metal terminals, allowing for a simpler manufacturing process that forms an electrical connection configuration without the need for metal stamping and injection molding, and incorporates sealing materials to prevent moisture infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional insulated rubber core and metal terminal configuration is used, then electrical connection functionality is achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent extracts and removes the conventional insulated rubber core and metal terminal components from the electrical connector structure. Instead, it uses a circuit board with electrical conductors and soldering pads that are directly disposed on the circuit board, eliminating the need for separate rubber core and metal terminal components and their associated complex manufacturing processes.
Solution Approach 2:
The patent replaces expensive metal terminals and rubber cores with a circuit board structure that uses standard PCB manufacturing processes. The electrical conductors are formed on the circuit board using conventional PCB techniques, which are more cost-effective and simpler than the traditional metal stamping and injection molding processes.
2Ease of manufacture
If metal stamping and injection molding processes are used, then metal terminals are formed, but manufacturing cost increases
Solution Approach 1:
The patent replaces the mechanical processes of metal stamping and injection molding with PCB manufacturing processes. The electrical conductors are formed on the circuit board using standard PCB techniques such as copper plating and solder mask application, which offer better precision and lower cost compared to traditional mechanical forming processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs and complexity while achieving the same electrical connection functionality as conventional connectors, with enhanced sealing to prevent moisture ingress.
Implementation Method 1
The plurality of first soldering pads are disposed on the second surface and are electrically connected with the electrical conductors
Data Source
AI summary
An electrical connector and a manufacturing method for the same. The electrical connector comprises a housing member and a plugging module. One end of the housing member is provided with a mating interface. An accommodating space communicating with the mating interface is provided in the housing member. The plugging module comprises a first circuit board, a plurality of electrical conductors and a plurality of first soldering pads. The first circuit board is disposed in the accommodating space. The first circuit board comprises a first surface and a second surface opposite to the first surface. The plurality of electrical conductors are disposed on the first surface and/or the second surface and is close to the mating interface. The plurality of first soldering pads are disposed on the second surface and are electrically connected with the plurality of electrical conductors.